SEAT Workshop Service and Repair Manuals

Dismantling and assembling output shaft for 5th, 6th and reverse gears

Special tools and workshop equipment required

t	Thrust plate -VW 401-

t	Thrust plate -VW 402-

t	Press tool -VW 407-

t	Press tool -VW 408 A-

t	Press tool -VW 412-

t	Tube -VW 415 A-

t	Support plate -VW 309-

t	Gearbox support -VW 353-

t	Thrust piece -VW 433-

t	Thrust piece -VW 454-

t	Support rail -VW 457-

t	Support plate -VW 801-

t	Thrust piece -VW 431-

t	Installing sleeve -VW 455-

t	Thrust pad -VW 510-

t	Tube -VW 516-

t	Tube -VW 519-

t	Thrust plate -30-11-

t	Thrust plate -40-105-

t	Drift sleeve -40-20-

t	Thrust piece -2050-

t	Tube -3296-

t	Tapered roller bearing puller -V.A.G 1582-

t	Adapter -V.A.G 1582/4-

t  Adapter -V.A.G 1582/7-

t  -1-Internal puller -Kukko 21/7- t  -3-Splitter -Kukko 17/2- t  -4-Counterhold -Kukko 22/2-

t	If output shaft or tapered roller bearings have been renewed, adjust output shaft → Chapter.

t	Always renew both tapered roller bearings together as a set.

1 -	Clutch housing

2 -

Washer

q	Always 0.65 mm thick

3 -	Tapered roller bearing outer race

q	Pulling out → Fig.

q	Pressing in → Fig.

4 -	Tapered roller bearing inner race

q	Pulling off → Fig.

q	Pressing on → Fig.

5 -	Output shaft

q	For 5th, 6th and reverse gears

q	Adjusting → Chapter

6 -	Reverse gear synchro-hub

q	Pressing off → Fig.

q	Installation position → Fig.

q	Pressing on → Fig.

7 -	Retaining ring

q	Always renew

8 -	Reverse gear locking collar

q	With retaining ring

9 -	Needle bearing

q	For reverse gear synchromeshed gear

10 -	Synchromeshed gear for reverse gear

11 -

Sleeve

q	Press off with reverse gear synchromeshed gear → Fig.

q	Installation position: wide shoulder of sleeve faces reverse gear synchromeshed gear

q	Pressing on → Fig.

12 -	Retaining ring

q	Always renew

13 -	Needle bearing

q	For 6th gear

14 -	Synchromeshed gear for 6th gear

15 -	Synchro-ring for 6th gear

q	Check for wear → Fig.

16 -	Locking collar with synchro-hub for 5th and 6th gears

q	After removing retaining ring → Item, press off with synchromeshed gear for 6th gear → Fig.

q	Dismantling → Fig.

q	Assembling locking collar and synchro-hub → Fig. and → Fig.

q	Pressing on → Fig.

17 -	Retaining ring

q	Always renew

18 -	Needle bearing

q	For 5th gear

19 -	Synchro-ring for 5th gear

q	Check for wear → Fig.

20 -	Synchromeshed gear for 5th gear

21 -	Tapered roller bearing inner race

q	Pulling off → Fig.

q	Pressing on → Fig.

22 -	Retaining ring

q	If tapered roller bearing → Item and output shaft → Item are renewed, redetermine → Fig.

23 -	Tapered roller bearing outer race

q	Pulling out → Fig.

q	Pressing in → Fig.

24 -

Shim

q	Determining thickness → Chapter

25 -	Gearbox housing

26 -

Spring

q	Installation position → Fig.

27 -	Locking collar

28 -	Synchro-hub

29 -	Locking pieces (Qty. 3)

q	Installation position → Fig.

Pulling out tapered roller bearing outer race A -  Counter support, e.g. -Kukko 22/2- B -  Internal puller, 46 ... 58 mm, e.g. -Kukko 21/7-   Note After pulling out, check washer for damage and renew if necessary.

Pressing tapered roller bearing outer race into clutch housing –  Fit washer under outer race. –  Support clutch housing with drift sleeve -40-20- directly below bearing support.

Pulling off tapered roller bearing inner race –  First remove retaining ring. –  Before setting up pulling device, set thrust piece -VW 431- and thrust plate -40-105- on output shaft.

Pressing off synchro-hub and locking collar for 5th and 6th gears with synchromeshed gear for 6th gear –  First remove retaining ring.

Pressing off sleeve -A- with reverse gear synchromeshed gear. –  First remove retaining ring.

Pressing off reverse gear synchro-hub –  First remove retaining ring. A -  Splitter, 22...115 mm, e.g. -Kukko 17/2-

Pulling off tapered roller bearing inner race –  Before setting up pulling device, set thrust plate -30-11- on output shaft.

Installation position of reverse gear synchro-hub Stop of reverse gear locking collar -arrow A- faces teeth of output shaft -arrow B-.

Pressing on reverse gear synchro-hub –  Install retaining ring.

Pressing on sleeve -A- Installation position: Wide collar faces reverse gear synchromeshed gear. –  Install retaining ring.

Checking synchro-rings for 5th and 6th gear for wear –  Press synchro-ring onto cone of synchromeshed gear and measure gap “a” using feeler gauge.

Gap “a”	Installation (new) dimension	Wear limit
5th and 6th gears	1.0…1.7 mm	0.5 mm

Dismantling and assembling locking collar and synchro-hub for 5th and 6th gears 1 -  Spring 2 -  Locking piece 3 -  Locking collar 4 -  Synchro-hub –  Slide locking collar over synchro-hub. Notches for locking pieces in synchro-hub and locking collar must align.

Assembling locking collar with synchro-hub for 5th and 6th gears Locking collar has been pushed over synchro-hub. –  Insert locking pieces and install springs offset 120°. Angled end of spring must locate in hollow locking piece.

Assembling locking collar with synchro-hub for 5th and 6th gears Some locking collars have a chamfer on their outer diameter Installation position: The chamfer on the outer diameter of the locking collar points towards the 5th gear synchromeshed gear –  Install retaining ring.

Pressing on tapered roller bearing inner race –  Determine and install retaining ring → Fig..

Determining thickness of retaining ring –  Determine thickest retaining ring which will still fit and install it. –  Determine retaining ring from table. Part numbers → Electronic parts catalogue (ETKA). Available retaining rings

Thickness (mm)
1.79	1.89	1.98
1.83	1.92
1.86	1.95

Pressing on tapered roller bearing inner race

Pulling outer race for tapered roller bearing out of gearbox housing A -  Counter support, e.g. -Kukko 22/2- B -  Internal puller, 46 ... 58 mm, e.g. -Kukko 21/7-

Pressing tapered roller bearing outer race into gearbox housing –  Support gearbox housing with thrust piece -2050- below bearing support.